Processed slabs, and systems and methods related thereto

ABSTRACT

This document describes systems and processes for forming synthetic molded slabs, which may be suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

CROSS-REFERENCE TO RELATED APPLICATION(S)

This is a continuation application of U.S. patent application Ser. No.16/360,628, filed Mar. 21, 2019, which is a continuation of U.S. patentapplication Ser. No. 15/044,599, filed Feb. 16, 2016 (now U.S. Pat. No.10,252,440), which is a divisional application of U.S. patentapplication Ser. No. 15/042,881, filed on Feb. 12, 2016 (now U.S. Pat.No. 10,195,762), which is a continuation of U.S. patent application Ser.No. 14/610,172, filed on Jan. 30, 2015 (now U.S. Pat. No. 9,289,923),the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

This document describes systems and processes for forming synthetic moldslab products, for example, a synthetic mold slab that is thermoformedor otherwise compacted to a selected slab shape from a mixture includingparticulate mineral material, resin binder, and pigments so that thesynthetic molded slab is suitable for use in living or working spaces(e.g., along a countertop, table, floor, or the like).

BACKGROUND

Quarried stone slabs are a commonly used building material. Granite,marble, soapstone, and other quarried stones are often selected for useas countertops due to their aesthetic properties. Despite the visualappeal of quarried stone, quarried stones can be quite expensive toobtain and are generally limited to naturally occurring color schemes.

Engineered stone slabs may be formed from a man-made combination ofmaterials that can provide improved stain-resistant or heat-resistantproperties compared to quarried stone. Engineered stone is typically acombination of particulate mineral material and binder, such as apolymer resin or cement. Some engineered stones partly emulate someaesthetic properties of quarried stone, but still fall noticeably shortof the complicated look and texture of quarried stone.

SUMMARY

Some embodiments described herein include systems and processes forforming synthetic molded slabs suitable for use in living or workingspaces (e.g., along a countertop, table, floor, or the like). Inparticular embodiments, the synthetic molded slabs can be manufacturedusing, for example, a set of stencils that separate differentlypigmented particulate mineral mixes into predetermined regions of aseries of molds, thereby providing molded slabs having a similarappearance to one another (which, unlike quarried stone slabs taken froma quarry, can be generally repeatable and predefined as part of themanufacturing process). As used herein, “differently pigmented” meanshaving different pigment combinations or otherwise having a differentvisual apparent in color tone or visual texture. In such embodiments,however, the appearance of each synthetic molded slab can provide thecomplex striations and veining patterns that emulate a quarried stoneslab. For example, each slab can be formed from a combination ofdifferently pigmented particulate mineral mixes that are separatelydispensed into two or more partial molds which combine to facilitate theselected striations and veining patterns. The slabs may be subsequentlyprocessed by compression molding and curing operations.

Particular embodiments described herein include a process of forming asynthetic molded slab from different particulate mineral mixes. Theprocess may include sequentially dispensing at least first and secondpigmented particulate mineral mixes comprising predominantly a quartzmaterial into a single slab mold using at least first and seconddistributors. The first distributor may output the first pigmentedparticulate mineral mix through a first stencil positioned over the slabmold and into the slab mold according to a first stencil pattern, andthe second distributor may subsequently output the second pigmentedparticulate mineral mix through a second stencil positioned over theslab mold and into the slab mold according to a second stencil patternsuch that the second pigmented particulate mineral mix is deposited inregions of the slab mold that are unoccupied by the first pigmentedparticulate mineral mix. The process may further include vibratingand/or compacting the pigmented particulate mineral mixes arranged inthe slab mold so as to form a synthetic molded slab that is generallyrectangular and has major surface. In various embodiments, the majorsurface may have a width or at least 3 feet and a length of at least 6feet. Optionally, the aforementioned vibrating and compacting of thepigmented particulate mineral mixes arranged in the slab mold may beperformed contemporaneously. Additional embodiments described hereininclude a synthetic molded slab formed according to this particularprocess.

Some embodiments described herein include a process of forming asynthetic molded slab from a set of different particulate mineral mixesthat each include a quartz material, one or more pigments, and one ormore resin binders. The process may include outputting a firstparticulate mineral mix of the set of different particulate mineralmixes from a first distributor and through a first stencil that ispositioned over a slab mold and that defines a first pattern of firstdesign apertures surrounded by first occluded regions. The process mayfurther include depositing the first particulate mineral mix passingthrough the first design apertures into the slab mold so as to partlyfill a mold space of the slab mold that is at least 6 feet long by atleast 3 feet wide. The process may also include moving the partly filledslab mold relative to the first stencil so that a second stencil ispositioned over the partly filled slab mold, and the second stencil maydefine a second pattern of second design apertures surrounded by secondoccluded regions. The process may further include outputting a secondparticulate mineral mix of the set of different particulate mineralmixes from a second distributor and through the second design aperturesof the second stencil. Also, the process may include depositing thesecond particulate mineral mix passing through the second designapertures into the slab mold and into regions of the mold space of theslab mold that are unoccupied by the first pigmented particulate mineralmix. Further, the process may include vibrating and compacting (whichare optionally performed contemporaneously) the pigmented particulatemineral mixes arranged in the slab mold so as to form a synthetic moldedslab that is generally rectangular and has major surface with a width orat least 3 feet and a length of at least 6 feet. Additional embodimentsdescribed herein include a synthetic molded slab formed according tothis particular process.

In one aspect of this process, the first particulate mineral mix and thesecond particulate mineral mix may comprise at least two differentlycolored mineral mixes that each include the quartz material, one or morepigments, and at least one binder. In second aspect of this process, thedepositing of the first particulate mineral mix may include distributingthe first particulate mineral mix according to a first predefinedpattern, and the depositing the second particulate mineral mix mayinclude distributing the second particulate mineral mix according to asecond predefined pattern. In a third aspect of this process, the firstpredefined pattern may define a first pigmented vein, and the secondpredefined pattern may define a second pigmented vein of the slab. In afourth aspect of this process, at least a portion of the first pigmentedvein may surround at least a portion of the second pigmented vein. In afifth aspect, the process may further include polishing the majorsurface of the slab. In a sixth aspect, the process provides the slab ina manner that emulates the appearance of a quarried stone slab due atleast in part to the two differently colored mineral mixes distributedaccording to the first predefined pattern and the second predefinedpattern. In a seventh aspect of this process, the depositing the firstparticulate mineral mix may include depositing the first particulatemineral mix into the slab mold according to a first predefined andrepeatable pattern, and the depositing the second particulate mineralmix may include depositing the second particulate mineral mix into theslab mold according to a second predefined and repeatable pattern so asto define complementary regions of multiple different particulatemineral mixes.

Further embodiments described herein include a system for forming asynthetic molded slab using a combination of different particulatemineral mixes. The system may include at least one slab mold defining amold space that is at least 6 feet long by at least 3 feet wide. Also,the system may include two or more stencils defining complementarypatterns of open spaces and occluded spaces, and the cumulative areas ofthe open spaces of the stencils corresponding to substantially the moldspace of the particular slab mold. The system may further include two ormore mineral aggregate distributors that are each configured to dispensea corresponding particulate mineral mix into the slab mold through acorresponding one of the stencils. Each stencil may be configured toprevent a mix in the distributor from accessing selected areas of eachmold in the series of molds.

Some embodiments described herein include a set of separately moldedsynthetic slabs having a substantially repeated rectangular majorsurface appearance defined by a set of particulate mineral mixes. Eachrespective slab of the set may include at least two differentparticulate mineral mixes distributed according to at least twopredefined stencil patterns for each of the synthetic slabs in the setof separately molded synthetic slabs. A first mix of the at least twodifferent particulate mineral mixes occupies a full thickness eachrespective slab at first regions in which a second mix of the at leasttwo different particulate mineral mixes is absent, and the second mix ofthe at least two different particulate mineral mixes occupies the fullthickness of each respective slab at second regions in which the firstmix of the at least two different particulate mineral mixes is absent.Optionally, the at least two different particulate mineral mixes mayeach comprise a quartz material, one or more pigments, and one or moreresin binders. Also, each respective slab is rectangular and has majorsurface with a width or at least 3 feet and a length of at least 6 feet.

Particular embodiments described herein include a synthetic molded slabthat optionally comprises at least a quartz material. The syntheticmolded slab may include a major surface defined by a set of particulatemineral mixes and having a rectangular shape that is at least 2 feetwide by at least 6 feet long and extending perpendicularly to a slabthickness. The major surface may have at least a first pigmented veinpattern defined by a first stencil pattern and a second pigmented veinpattern defined by a second stencil pattern that is a negative of thefirst stencil pattern. The first pigmented vein pattern may include afirst particulate mineral mix that occupies the slab thickness at a setof first regions that collectively provide the first pigmented veinpattern, and the second pigmented vein pattern may include a secondparticulate mineral mixes that occupies the slab thickness at a set ofsecond regions that collectively provide the second pigmented veinpattern. The first particulate mineral mix may be absent from the set ofsecond regions, and the second particulate mineral mix may be absentfrom the set of first regions. The first and second particulate mineralmixes may be differently pigmented, and each of the particulate mineralmixes may optionally comprise the quartz material, one or more pigments,and one or more binders.

The systems and techniques described here may provide one or more of thefollowing advantages. First, a system can be used to produce a pluralityof synthetic molded slabs that each have similar striations and veiningpatterns and that are suitable for use in living or working spaces(e.g., along a countertop, table, floor, or the like). Such slabs can beformed from a combination of differently pigmented particulate mineralmixes that are vertically distributed into designated regions of eachmold according to predefined and complementary dispensation patterns(e.g., two or more horizontally oriented templates that can bepositioned over each mold), which provide the selected striations andveining patterns that are generally repeatable for each separatelymolded slab.

Second, each slab in the system can be formed from a compression moldingoperation in which the molds containing the particulate mineral mixesare maintained in a horizontal orientation after the mold is filled. Forexample, the differently pigmented particulate mineral mixes arevertically poured through a series of complementary, horizontallyoriented templates, the filled mold is shifted horizontally for asubsequent compression molding operation (e.g., vibro-compactionmolding, curing, etc.). From there, some or all of the mold is removedfrom the hardened slab so that at least a major surface of the slab ispolished to provide an appearance of the complex striations and veiningpatterns that emulate a quarried stone slab. In such circumstances, thepolished major surface of each of the synthetic molded slabs provides anouter appearance that is remarkably similar to the other slabs in theset of separately molded slabs, unlike quarried stone slabs taken from aquarry. Moreover, the pigments and particulate mineral mixes can beselected to provide color combinations and visual effects that improvedupon and offer a variety of color combination options far beyond what isavailable from quarried stone slabs taken from a quarry.

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features andadvantages will be apparent from the description and drawings, and fromthe claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a synthetic molded slab after formation,in accordance with some embodiments.

FIGS. 2A and 2B are exploded and assembled views of an example of afirst partial slab stencil aligned with a slab mold, in accordance withsome embodiments.

FIGS. 3A and 3B are exploded and assembled views of an example of asecond partial slab stencil that is complementary to the first partialslab stencil of FIGS. 2A and 2B, the second partial slab stencil beingaligned with the slab mold of FIGS. 2A and 2B.

FIG. 4 is a diagram of an example system for forming a synthetic moldedslab product.

FIGS. 5A-5D are diagrams of a synthetic molded slab during and afterfilling of two partial slab stencils.

FIG. 6 is a perspective view of an example synthetic molded slab productformed by the system of FIG. 4.

FIG. 7 is a flow diagram of an example process for forming a syntheticmolded slab product.

DETAILED DESCRIPTION

Referring to FIG. 1, a system can be used to produce one or moresynthetic molded slabs 50 having a number of striations or veinsaccording to a predefined pattern. Each slab 50 can comprise a quartzmaterial and/or other particulate mineral material that, when mixed withpigments and a resin binder and compressed, provides a hardened slabproduct suitable for use in living or working spaces (e.g., along acountertop, table, floor, or the like). As shown in FIG. 1, each slab 50can be formed from a combination of differently pigmented particulatemineral mixes that are vertically poured into different, designatedregions of a respective mold (while the mold is horizontally oriented inthis embodiment). These designated regions are repeated for each mold ina series of molds (described in more detail below) due to, for example,a set of stencil structures that can be positioned over each mold andthat provide a predefined complementary and repeatable dispensationpattern for the differently pigmented particulate mineral mixes in eachmold. In some embodiments described herein, the predefined complementaryand repeatable dispensation pattern for the differently pigmentedparticulate mineral mixes provides the selected striations and veiningpatterns that are generally repeatable for each separately molded slab.As will be discussed in further detail in the descriptions of FIGS.2A-7, some embodiments described herein employ a first partial stencilis arranged above a horizontal slab mold, and a first pigmentedparticulate mix is dispensed though open portions of the stencil intothe mold. One or more successive stencils (e.g., at least a secondpartial stencil) are positioned over the same mold that is partiallyfilled with the first pigmented particulate mix in predefined regions,and one or more differently pigmented particulate mixes (e.g., at leasta second pigmented particulate mix) are sequentially dispensed throughopen portions of the successive stencils into the mold until all regionsof the mold are filled. The mold may be subsequently transported in thehorizontal orientation for compaction, curing, and other operations.

As shown in FIG. 1, depending upon the predefined dispensation patternof the complementary partial stencils, the dispensation process canprovide an aesthetic effect that emulates the veined appearance ofnatural quarried stone slabs such as granite or marble, including someveins 51 and 52 that extend partly or fully across a complete length Lof the hardened slab 50 (e.g., at least 3 feet wide by at least 6 feetlong, and between about 3 feet and 6 feet wide and between about 6 feetand 12 feet long, between about 4.5 feet and 5.5 feet wide and betweenabout 10 feet and 11 feet long, and preferably a size selected from oneof about 4.5 feet wide by about 10 feet long or about 5.5 feet wide byabout 11 feet long). Not only can such differently pigmented veins 51and 52 extend across the full length of the slab product, but such veins51 and 52 can also extend through the thickness of the slab 50 (therebyproviding a natural vein appearance even when the slab is cut and edgedto specific shapes in living or working spaces (e.g., along acountertop, table, floor, or the like). Because each slab 50 in the setof separately molded slabs can include the layers of differentparticulate mineral mixes dispensed into the mold according to thepredefined and repeatable dispensation patterns of complementarystencils, multiple slabs 50 in the set of separately molded slabs canhave substantially the same appearance to one another.

In this embodiment depicted in FIG. 1, the slab 50 comprises twodifferent particulate mineral mixes that are separately dispensed intothe mold 130 through two complementary stencils (e.g., a first stencilthat is essentially a negative of a second stencil). However, in someembodiments, three or more stencils may be used to repeatably patternthe distribution of three or more different particulate mineral mixesthat are separately dispensed into the mold 130. The different mixesdispensed into each mold according to the repeatable pattern can becompaction molded and cured in the mold (described in more detail below)so as to provide the hardened slab 50 of composite stone material. Oneor more of the mixes that are used to form the composite stone materialcan include organic polymer(s) and inorganic (mineral) particulatecomponent. The inorganic (mineral) particulate component may includesuch components as silicon, basalt, glass, diamond, rocks, pebbles,shells, a variety of quartz containing materials, such as, for example,but not limited to: crushed quartz, sand, quartz particles, and thelike, or any combination thereof. In this embodiment, all of thedifferent particulate mineral mixes each comprise a quartz material as apredominant component, which may include sand of various particle sizesand of different combinations. In the hardened slab 50, the organic andinorganic materials can be linked using a binder, which may include forexample, mono-functional or multifunctional silane molecules,dendrimeric molecules, and the like, that may have the ability to bindthe organic and inorganic components of the composite stone mix. Thebinders may further include a mixture of various components, such asinitiators, hardeners, catalysators, binding molecules and bridges, orany combination thereof. Some or all of the mixes dispensed in the moldmay include components that are combined in a mixing apparatus (notshown) prior to being conveyed to the mold. The mixing apparatus can beused to blend raw material (such as the quartz material, organicpolymers, unsaturated polymers, and the like) at various ratios. Forexample, some or all of the mixes dispensed in the mold may includeabout 8-95% quartz aggregates to about 5-15% polymer resins. Inaddition, various additives, may be added to the raw materials in themixing apparatus, such additives may include, metallic pieces (e.g.,copper flecks or the like), colorants, dyes, pigments, chemicalreagents, antimicrobial substances, fungicidal agents, and the like, orany combination thereof.

Preferably, the mold at least partially defines a length L and a width Wof the hardened slab 50 (because the mold retains the particulatemineral mixes therein throughout the subsequent compaction and curingprocesses). In some embodiments, the width W of the slab 50 formed inthe mold is at least 3 feet, between about 3 feet and 6 feet, andpreferably about either 4.5 feet, and the length L of the slab 50 formedin the mold is at least 6 feet, and between about 6 feet and 12 feet,preferably about 10 feet. In some implementations, the mold may be sizedto form larger (e.g., “jumbo”) slabs, where the width W of the slab 50formed in the mold is about 5 feet to about 6 feet (e.g., preferablyabout 5.5 feet) and the length L of the slab 50 formed in the mold isabout 10.5 feet to about 12 feet (e.g., preferably about 11 feet). Assuch, even though each slab 50 can be relatively large in length L, someor all of the veins 51, 52 can nevertheless extend across the fulllength of the slab 50. In some embodiments, the thickness T of the slab50 formed is at least 1 inch, between about 1 inch and 5 inches, andpreferably about 3 inches.

Referring now to FIGS. 2A and 2B, exploded and assembled views of anexample of a first partial slab stencil 200. Referring to FIG. 2A, aslab mold 130 and the partial slab stencil 200 are shown in an explodedand inverted view. The slab mold 130 includes a planar mold floor 132bounded by a collection of mold walls 131 extending perpendicular fromthe planar mold floor, defining a generally tray-like shape.

The partial slab stencil 200 includes an outer frame 202 having a lengthand width that approximates that of the slab mold 130. In someembodiments, the slab mold 130 can be at least 3 feet, between about 3feet and 5 feet, and preferably about 4 feet, and the length L of theslab 50 formed in the mold is at least 6 feet, and between about 6 feetand 10 feet, preferably about 8 feet. In some implementations, the slabmold may be sized to form larger (e.g., “jumbo”) slabs, where the widthW of the slab 50 formed in the mold is at least 5 feet (e.g., about 5.5ft) and the length L of the slab 50 formed in the mold is at least 10feet (e.g., about 11 ft). In some embodiments, the slab mold 130 canhave a thickness T of at least 1 inch, between about 1 inch and 5inches, and preferably about 3 inches.

The outer frame 202 that supports a collection of occluded regions 204and defines a collection of design apertures 206. The outer frame 202and/or the occluded regions 204 can be formed from metal (e.g., steel,aluminum), plastic, wood, composite (e.g., fiberglass, carbon fiber),rubber, or combinations of these and/or any other appropriate material.In some embodiments, the outer frame 202 and/or the occluded regions 204can include non-stick materials or coatings that can resist adhesionwith the ingredients of particulate mineral mixes.

The occluded regions 204 extend beyond the outer frame 202 a distanceapproximately equal to the thickness T of the slab mold 103. When thepartial slab stencil 200 is assembled with the slab mold 130, as shownin FIG. 2B, the outer frame 202 rests upon the mold walls 131 of theslab mold 130, and the occluded regions 204 extend substantially throughthe thickness T of the slab mold 130 to contact the planar mold floor132. As will be discussed further in the descriptions of FIGS. 4-7, whenthe partial slab stencil 200 is assembled with the slab mold 130, thedesign apertures 206 define spaces within the slab mold into which aparticulate mineral mix can be dispensed, while the occluded regions 204prevent the mix from entering.

Referring now to FIGS. 3A and 3B, exploded and assembled views of anexample of a second partial slab stencil 300. Referring to FIG. 3A, thesame slab mold 130 (previously depicted in FIGS. 2A and 2B) and thesecond partial slab stencil 300 are shown in an exploded and invertedview. Generally speaking, in this embodiment, the second partial slabstencil 300 is complementary to the first partial slab stencil 200(FIGS. 2A and 2B). For example, areas that are occluded in the firstpartial slab stencil 200 are generally open in the second partial slabstencil 300, and areas that are open in the first partial slab stencil200 are generally occluded in the second partial slab stencil 300. Insome embodiments, the first partial slab mold 200 may define a“positive” pattern while the second partial slab stencil 300 defines a“negative” pattern that corresponds inversely to the “positive” pattern.

The second partial slab stencil 300 includes an outer frame 302 having alength and width that approximates that of the slab mold 130. The outerframe 302 that supports a collection of occluded regions 304 and definesa collection of design apertures 306. The outer frame 302 and/or theoccluded regions 304 can be formed from metal (e.g., steel, aluminum),plastic, wood, composite (e.g., fiberglass, carbon fiber), rubber, orcombinations of these and/or any other appropriate material. In someembodiments, the outer frame 302 and/or the occluded regions 304 caninclude non-stick materials or coatings that can resist adhesion withthe ingredients of particulate mineral mixes.

The occluded regions 304 extend beyond the outer frame 302 a distanceapproximately equal to the thickness T of the slab mold 103. When thesecond partial slab stencil 300 is assembled with the slab mold 130, asshown in FIG. 3B, the outer frame 302 rests upon the mold walls 131 ofthe slab mold 130, and the occluded regions 304 extend substantiallythrough the thickness T of the slab mold 130 to contact the planar moldfloor 132. As will be discussed further in the descriptions of FIGS.4-7, when the second partial slab stencil 300 is assembled with the slabmold 130, the design apertures 306 define spaces within the slab mold130 into which a particulate mineral mix can be dispensed, while theoccluded regions 304 prevent the mix from entering. In some embodiments,three or more partial slab stencils with design apertures thatcumulatively correspond substantially to the length and width of theslab mold can be used (for sequentially dispensing a correspondingnumber of differently pigmented particulate mixes).

Referring now to FIG. 4, in some embodiments, a system 400 for forming aset of synthetic molded slab products (e.g., the slab 50 in FIG. 1) isconfigured to sequenitally dispense differently pigmented particulatemineral mixes through two or more complementary partial slab stencilsand into the same horizontally oriented mold, which is then processedusing a subsequent compression molding operation (e.g., vibro-compactionmolding, curing, etc.). The system 400 in the depicted embodimentincludes an input conveyor 410 and an output conveyor 420. A collectionof slab molds 130 are transported on the input conveyor 410. The slabmolds 130 provide a form for synthetic molded slab products that are atleast three feet wide and at least six feet long. The input conveyor 410transports the slab molds 130 to an air table 440. The air table 440includes a collection of outlets formed on a top surface. Air pumpedthrough the outlets forms a cushion of air between the top surface andthe slab molds 130, to help operators move and/or orient the slab molds130.

Still referring to FIG. 4, the system 400 also includes a collection ofmineral aggregate distributors 460 a, 460 b. In this embodiment, each ofthe distributors 460 a, 406 b is dedicated to dispensing a correspondingparticulate mineral mix (refer to FIG. 1). In this embodiment, thepartial slab stencil 200 is temporarily assembled to the slab mold 130.The slab mold 130 is moved horizontally (e.g., relative to gravity)beneath the distributor 460 a, partly filling the slab mold 130 with afirst particulate mineral mix. The partial slab stencil 200 isdisassembled from the slab mold 130, and the partial slab stencil 300 istemporarily assembled to the partly filled slab mold 130. The slab mold130 is moved horizontally (e.g., relative to gravity) beneath thedistributor 460 b, partly filling the slab mold 130 (e.g., thecomplementary areas left unfilled by the partial slab stencil 200) witha second particulate mineral mix. Additional details of this particularembodiment of the partial slab stencils 200, 300 are described furtherin connection with FIGS. 5A-7.

For example, in this embodiment, the first and second partial slabstencils 200, 300 are configured to receive two differently pigmentedmineral mixes (comprising mostly a quartz material as described above),so there are two corresponding distributors 460 a, 406 b. In thisembodiment, each of the mineral aggregate distributors 460 a, 460 bincludes a dispensing head 462. In use, the dispensing heads 462 eachreceive a corresponding particulate mineral mix from a different mixerline (not shown), such that each dispenser head 462 is configured torelease a different particulate mineral mix (e.g., different pigments,different mineral compositions, different additives, or a combinationthereof) compared to the other dispenser heads 462. Each dispenser head462 is configured to controllably dispense its supply of correspondingparticulate mineral mix through the apertures 206, 306 of acorresponding one of the partial slab stencils 200, 300. For example,the dispensing heads 462 are each configured with a shutter or valveapparatus (not shown) that is controllable to regulate the flow ofparticulate mineral mix from the dispensing head 462 to the slab mold130. The dispensing heads 462 are controllable dispense fillers into theslab molds 130 at a substantially repeatable rate. Additional details ofthis particular embodiment of the dispensing head 462 are describedfurther in connection with FIGS. 5A-6B.

In the illustrated example, two mineral aggregate distributors 460 a,406 b and two partial slab stencils 200, 300 are used, although in otherexamples, the slab may be formed from between 2 and 20 differentparticulate mineral mixes, and more preferably between 3 and 8 differentparticulate mineral mixes (thereby providing a system that would includea corresponding number of distributors and partial slab stencils). Insome examples, the number of mineral aggregate distributors and partialslab stencils can correspond equally to the number of differentlypigmented particulate mineral mixes used to create the hardened slabproduct.

After the slab mold 130 has been sufficiently filled, the partial slabstencil 300 is disassembled from the slab mold 130. The slab mold 130(now a filled mold 480) is moved on a cushion of air provided by an airtable 470, to an output conveyor 120. As shown in FIG. 1, the successivecomplementary patterns of different particulate mineral mixes that weredispensed into the mold 130 are generally noticeable in the filled molds480 and are arranged in the horizontal orientation on the outputconveyer 420. Some or all of these successive complementary patterns ofdifferent particulate mineral mixes can form the repeatably patternedveins of the hardened slab (e.g., the slab 50 in FIG. 1, the slab 600 inFIG. 6, or the like).

Optionally, the system 400 may include a secondary dispenser (notshown), which may be positioned so that each filled mold 480 passesunder the secondary dispenser. The secondary dispenser can be configuredto dispense a material that is used to define one more generally“widthwise” veins. Optionally, these widthwise veins may be thinner andspread further apart than the veins defined by the successivecomplementary patterns of different particulate mineral mixes. Also,these widthwise veins may be formed from a material having a differentpigmentation than the particulate mineral mixes dispensed from thedistributors 460 a, 460 b. In some embodiments, the secondary dispensermay be configured with a shutter or valve apparatus (not shown) that iscontrollable to regulate the flow of pigmented material, therebyproviding a predetermined pattern of the widthwise veins that isrepeatable for each of the filled molds 480 pass under the secondarydispenser. In some embodiments, the secondary dispenser can beconfigured to dispense a pigment powder material (e.g., not mixed withquartz material). In other embodiments, the secondary dispenser can beconfigured to dispense a particulate mineral mix (including a quartzmaterial) having pigments that are different from the mixes dispensedfrom the distributors 460 a, 460 b. In some embodiments, the pigmentpowder material (or other material) dispensed from the secondarydispenser can be deposited along a major (exposed) side of the filledmold 480 so that at least a portion of the material penetrates at leastslightly into the thickness of the mineral mix material previouslypoured into the mold 480 (thereby permitting the widthwise veins toremain viewable even after compaction and polishing of the slab). Insuch circumstances, the widthwise veins may not extend through the fullthickness of the hardened slab (which is different from some or all ofthe veins defined by the successive complementary patterns of differentparticulate mineral mixes poured into the mold 130 by the distributors460 a, 460 b).

Still referring to FIG. 4, the output conveyor 420 can be configured totransport each of the filled molds 480 to one or more sequent stationsin the system 400 for forming the hardened slab. For example, each ofthe filled molds 480 can continue to a subsequent station in which a topmold attachment 494 is positioned over the filled mold 480 so as toencase the layers of particular mineral mixes between the mold 130 and atop cover mold piece (not shown in FIG. 4). From there, the filled mold480 (now including the top cover mold piece continues to a subsequentstation in which a vibro-compaction press 495 applies compactionpressure, vibration, and vacuum to the contents inside the filled mold480, thereby converting the particulate mixes into a rigid slab. Afterthe vibro-compaction operation, the filled mold 480 (with the compactedand hardened slab therein) proceeds to a curing station 496 in which thematerial used to form the slab (including any resin binder material) arecured via a heating process, thereby further strengthening the slabinside the filled mold 480. After the slab is fully cured (and cooled),the primary mold 130 and the top mold cover piece are removed from thehardened and cured slab at a mold removal station 497. The primary mold130 is then returned to the input conveyor 410. Then, the hardened andcured slab is moved to a polisher station 498, in which a major surfaceof the slab is polished to a smooth finish, thereby an appearance of thecomplex striations and veining patterns that emulate a quarried stoneslab. In such circumstances, the polished major surface of each of thesynthetic molded slabs provides an outer appearance that is generallyrepeatable for to the other slabs (from the other filled molds 480 inFIG. 4).

Now referring to FIG. 5A, the slab mold 130 is shown with the partialslab stencil 200. The slab mold 130 is partly filled by drawing thedistributor 460 a laterally across the partial slab stencil 200, or bypassing the partial slab stencil and the slab mold 130 laterally beneaththe distributor 460 a. The distributor 460 a holds a first particulatemineral mix, which is controllably released though the dispensing head462 into the slab mold 130. The collection of occluded regions 204 blockthe dispensation of the mix into predetermined areas of the slab mold130, while the collection of apertures 206 allow the mix to fillpredetermined areas of the slab mold 130, shown as a collection offilled regions 502.

Referring now to FIG. 5B, the slab mold 130 is shown with the partialslab stencil 200 removed after being partly filled according to thepattern provided by the partial slab stencil 200. As a result, the slabmold 130 is partly filled with the first particulate mineral mix in thefilled regions 502, and is partly unfilled in a collection of unfilledareas 504.

Now referring to FIG. 5C, the slab mold 130 is shown with the partialslab stencil 300. The collection of occluded regions 304 substantiallycorrespond to the collection of filled regions 502 (not visible in thisview) and substantially prevent the second mix from being dispensed as asecond layer upon the first mix already in the filled regions 502.Conversely, the collection of apertures 302 substantially correspond tothe collection of unfilled areas 504 left by the partial slab stencil200. For example the partial slab stencil 300 has a pattern that is thenegative of the pattern of the partial slab stencil 200, and thecollective combination of the apertures 202 and 302 substantiallycorrespond to the area (e.g., length L and width W) of the slab mold130.

The slab mold 130 is partly filled by drawing the distributor 460 blaterally across the partial slab stencil 300, or by passing the partialslab stencil and the slab mold 130 laterally beneath the distributor 460b. The distributor 460 b holds a second particulate mineral mix, whichis controllably released though the dispensing head 462 into the slabmold 130. The collection of occluded regions 304 block the dispensationof the mix into predetermined areas of the slab mold 130, while thecollection of apertures 306 allow the mix to fill the unfilled areas 504of the slab mold 130, shown as a collection of filled regions 506.

Referring now to FIG. 5D, the slab mold 130 is shown with the partialslab stencil 300 removed after being partly filled according to thepattern provided by the partial slab stencil 300. As a result, the slabmold 130 is partly filled with the first particulate mineral mix in thefilled regions 502, and is partly filled with the second particulatemineral mix in the filled regions 506.

In some embodiments, three or more partial slab stencils, distributors,and particulate mineral mixes can be used. For example, four partialslab stencils can be used in which each partial slab stencil has apredetermined pattern of apertures that do not overlap those of theother stencils, and collectively combine to substantially correspond tothe area of the slab mold 130. Four different particulate mineral mixes(e.g., with different aesthetic qualities) can be dispensed into thefour collections of apertures to create a four-color composite slab witha pattern that can be substantially repeated for multiple slabs.

Referring now to FIG. 6, an example synthetic molded slab product 600can be formed by the system of FIG. 4 using a combination of differentlypigmented particulate mineral mixes that are distributed according topredefined patterns of the two (or more) complementary partial slabtemplates 200 and 300 into the mold 130. In some embodiments, thesynthetic molded slab product 600 can provide a veined appearance thatemulates quarried stone slabs such as granite or marble, depending uponthe predefined dispensation pattern of the different particular mixes.For example, the major surface 612 of the slab 600 can be polished andprovide at least some veins 602, 606 that extend partly or fully acrossa length and/or width of the hardened slab 600. Not only can suchdifferently pigmented veins (602 and 606, for example) extend across theslab product, but such veins can also extend through the thickness 610of the slab 600 from the first major face 612 to the opposing major face614 (thereby providing a natural vein appearance even when the slab iscut and edged to specific shapes in living or working spaces (e.g.,along a countertop, table, floor, or the like). Optionally, at least themajor surface 612 of the slab 600 may include a plurality of secondaryveins (not shown) defined, for example, by a secondary dispenser. Someof these “secondary” veins can extend fully across a complete width ofthe hardened slab 600. Because each slab 600 in the set of separatelymolded slabs (refer, for example, to the system in FIG. 4) can includethe regions of different particulate mineral mixes dispensed into themold 130 according to the predefined and repeatable dispensationpatterns of the partial slab stencils, multiple slabs 600 in the set canhave similarly positioned veins in the major surface and can providesubstantially the same appearance to one another.

The synthetic molded slab 600 can be cut, milled, machined, or otherwiseprocessed to various shapes and sized (e.g., to provide custom-fitcountertop surfaces with optional holes for sinks, faucets, or otheramenities). For example, a section 630 is cut away from the syntheticmolded slab product 600. With the veins 602 and 606 extending into theinterior 606 and/or across the thickness 610, cutting and/or processingof the synthetic molded slab product 600 shows the veins 602 and 606 ina manner that emulates the aesthetics of cut quarried stone slabs.

FIG. 7 is a flow diagram of an example process 700 for forming asynthetic molded slab product (such as slab 50 or 600 described above).In some implementations, the system 400 of FIG. 4 can be used to performthe process 700. The process 700 may include the operation 702 ofpositioning a positive partial slab stencil in a slab mold. In such anoperation, a partial slab stencil, such as the partial slab stencil 200may be temporarily assembled to the slab mold 130. The process 700 mayalso include the operation 704 of dispensing a first particulate mineralmix through the positive stencil into the slab mold. For example, aspreviously described, a first pigmented mix comprising predominantly aquartz material (e.g., a mix including the particulate quartz material,one or more pigments, and one or more resin binders) can be fed into theslab mold 130 using the distributor 460 a (FIG. 4). Next, the process700 may include the operation 706 of removing the positive partial slabstencil, and may include the operation 708 of positioning a negativepartial slab stencil in a slab mold. In such operations, the partialslab stencil 200 may be removed, and the partial slab stencil 300 may betemporarily assembled to the slab mold 130.

The process 700 may also include the operation 710 of dispensing asecond particulate mineral mix through the negative stencil into theslab mold. For example, as previously described, a second pigmented mixcomprising predominantly a quartz material (e.g., a mix including theparticulate quartz material, one or more pigments, and one or more resinbinders) can be fed into the slab mold 130 using the distributor 460 b(FIG. 4). Next, the process 700 may include the operation 712 ofremoving the positive partial slab stencil. For example, the partialslab stencil 300 can be removed from the slab mold 130.

The process 700 may further include the operation 714 ofcontemporaneously vibrating and compacting the particulate mineral mixesarranged in the mold while the mold is in the horizontal orientation. Insuch circumstances, the operation 714 may provide a compacted slab ofcomposite stone material. Also, in some embodiments, the process 700 mayfurther include the operation 716 of curing the compacted slab. Theprocess 700 may also include the operation 718 of polishing a majorsurface of the slab to provide a veined appearance on the polishedsurface of the slab, including but not limited to the examples describedabove.

Although a number of implementations have been described in detailabove, other modifications are possible. For example, the logic flowsdepicted in the figures do not require the particular order shown, orsequential order, to achieve desirable results. In addition, other stepsmay be provided, or steps may be eliminated, from the described flows,and other components may be added to, or removed from, the describedsystems. Accordingly, other implementations are within the scope of thefollowing claims.

1.-20. (canceled)
 21. A process of forming a processed slab having awidth of at least 3 feet and a length of at least 6 feet and a slabthickness that defines a vertical orientation, the process comprising:dispensing a first pigmented particulate mineral mix comprisingpredominantly quartz through a stencil into a first set of regions usinga first distributor while horizontally oriented occluded regions andvertically oriented walls of the stencil prevent dispensation of thefirst pigmented particulate mineral mix into a second set of regions,wherein the occluded regions of the stencil define a vein pattern; afterdispensing the first pigmented particulate mineral mix, dispensing asecond pigmented particulate mineral mix comprising predominantly quartzinto the second set of regions, the second set of regions different thanthe first set of regions; vibrating and compacting the pigmentedparticulate mineral mixes to form the processed slab having a slabthickness and a major surface that is generally rectangular with thewidth of at least 3 feet and the length of at least 6 feet.
 22. Theprocess of claim 21, wherein the vein pattern comprises a first vein ina generally lengthwise direction and a second vein in a generallywidthwise direction.
 23. The process of claim 22, wherein the secondvein extends across an entire width of the slab.
 24. The process ofclaim 22, wherein the first vein in the generally lengthwise directionintersects the second vein in the generally widthwise direction.
 25. Theprocess of claim 22, wherein the stencil includes an outer frame thatsurrounds the occluded regions.
 26. The process of claim 23, wherein thevein pattern is at least partially defined by first and second opposingvertically oriented walls extending parallel to the slab thickness. 27.The process of claim 26, wherein the stencil comprises the first andsecond opposing vertically oriented walls extending parallel to the slabthickness.
 28. The process of claim 22, wherein a thickness of thevertically oriented walls of the stencil is greater than the slabthickness.
 29. The process of claim 21, wherein dispensing a secondpigmented particulate mineral mix comprises dispensing the secondpigmented particulate mineral mix using a second distributor, the seconddistributor comprising a dispensing head having a width that is lessthan a width of the second set of regions.
 30. The process of claim 22,wherein dispensing a second pigmented particulate mineral mix comprisesdispensing the second pigmented particulate mineral mix using a seconddistributor, the second distributor comprising a means for controllablyreleasing the second pigmented particulate mineral mix into the secondset of regions.
 31. The process of claim 21, wherein the dispensing ofthe second pigmented particulate mineral mix comprises dispensing thesecond pigmented particulate mineral mix through a second stencil. 32.The process of claim 21, wherein the first pigmented particulate mix atthe first set of regions is completely unmixed with the second pigmentedparticulate mix at the second set of regions after vibrating andcompacting the pigmented particulate mineral mixes.
 33. The process ofclaim 22, wherein the first pigmented particulate mineral mix occupiesan entire slab thickness extending perpendicularly to the major surfaceat the first set of regions, and the second pigmented particulatemineral mix occupies the entire slab thickness at the second set ofregions that collectively provide a second vein pattern.
 34. The processof claim 33, further comprising dispensing a third pigmented particulatemineral mix comprising predominantly quartz, wherein the third pigmentedparticulate mineral mix comprises a vein that does not extend throughthe entire slab thickness.
 35. The process of claim 21, furthercomprising, before dispensing a second pigmented particulate mineralmix, removing the stencil to expose the second set of regions.
 36. Theprocess of claim 21, wherein vibrating and compacting the pigmentedparticulate mineral mixes comprises compressing the pigmentedparticulate mineral mixes so that a ratio of the width of the processedslab to the slab thickness is between 36:1 and 72:1, and a ratio of thelength of the processed slab to the slab thickness is between 72:1 and144:1.
 37. The process of claim 21, wherein dispensing the firstpigmented particulate mineral mix comprises dispensing the firstpigmented particulate mineral mix onto a planar surface, and dispensingthe second pigmented particulate mineral mix comprises dispensing thesecond pigmented particulate mineral mix onto the planar surface, theprocess further comprising transporting the first and second pigmentedparticulate mineral mixes on the planar surface.
 38. A set ofsubstantially identical processed slabs individually formed according tothe process of claim
 21. 39. A process of forming a processed slab fromdifferent particulate mineral mixes, comprising: dispensing a firstpigmented particulate mineral mix comprising predominantly quartzthrough a stencil into a first set of regions using a first distributorwhile the stencil prevents dispensation of the first pigmentedparticulate mineral mix into a second set of regions, the stencilincluding a plurality of occluded regions and a frame that surrounds theoccluded regions; dispensing a second pigmented particulate mineral mixcomprising predominantly quartz into the second set of regions using asecond distributor, the second pigmented particulate mineral mixdispensed according to a predefined pattern that defines a pigmentedvein pattern, the pigmented vein pattern including a widthwise vein thatextends across an entire width of the slab, and the second set ofregions being different than the first set of regions; vibrating andcompacting the pigmented particulate mineral mixes to form a processedslab that is generally rectangular and has a major surface with a widthof at least 3 feet and a length of at least 6 feet and a slab thickness.40. The process of claim 39, wherein the stencil comprises first andsecond opposed walls oriented parallel to the slab thickness, thepredefined pattern at least partially defined by the first and secondopposed walls oriented parallel to the slab thickness.